Packaging System

This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63/571,700 filed on 29 Mar. 2024 and entitled “PACKAGING SYSTEM,” which application is expressly incorporated herein by reference in its entirety.

The disclosure is related to packaging systems and, more particularly, to systems, methods, features, and other elements directed to packaging systems.

Packaging systems are commonly used to enclose products for distribution, storage, sale, and use. Some of the typical objectives of packaging systems are to protect and/or preserve the products they contain. Recently, more emphasis has been placed on creating packaging systems that create unique consumer impressions or improve the experience of consumers when opening or otherwise interacting with packaging systems.

There continues to be a need to develop packaging systems that are protect the packaged items and provide an improved user experience.

The drawings are to illustrate example implementations and are not drawn to scale. It is understood that the inventions are not limited to the arrangements and instrumentalities shown in the drawings.

A better understanding of different embodiments of the disclosure may be had from the following description read with the drawings in which like reference characters refer to like elements.

While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. The dimensions, angles, and curvatures represented are to be understood as examples for purposes of illustration and are not necessarily shown in proportion.

It should be understood, however, there is no intention to limit the disclosure to the specific embodiments disclosed, but on the contrary, the intention covers all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure.

The labels used herein that indicate or suggest particular orientations of components are used for convenience and describe one of many possible configurations.

Referring to, an exploded view of an example embodiment of a packaging systemis illustrated. The packaging systemincludes a base box, a tray, and a lid. In some embodiments, the lidmay be optional.

The base boxincludes a bottom paneland a plurality of wall panelsthat extend from or are connected to the bottom panel. Each of the bottom paneland the plurality of wall panelshas an interior surface that cooperate to form an interior spaceof the base box. Similarly, each of the bottom paneland the plurality of wall panelshas an exterior surface that cooperate to form an exterior of the base box.

The trayincludes a primary paneland a plurality of flapsthat extend from the primary panel. In the illustrated embodiment, the plurality of flapsare integrally formed with the primary panel. As also shown in the illustrated embodiment, the primary panelincludes a recessthat is configured to have a product positioned therein. The recessmay be shaped so as to be able to receive the product therein and hold the product in place within the packaging system. In some embodiments, the primary panelmay include multiple recesses configured to hold multiple products or different parts or components of one or more products.

The traymay be formed of a moldable material or substrate. For instance, the traymay be formed of a pulp, plastic, paper foam, or other moldable material. One or more molds and/or presses may be used to mold the moldable material into the general shape of the tray. For instance, one or more molds and/or presses may be used to form the primary panelwith the recesstherein and the plurality of flaps. One or more cutting tools (e.g., die cutter, knives, etc.) may be used to cut or trim the trayto its final dimensions. Cutting or trimming the trayto its final dimensions may form the outer edges of the plurality of flaps.

The lidincludes a top paneland a plurality of wall panelsthat extend from or are connected to the top panel. Each of the top paneland the plurality of wall panelshas an interior surface that cooperate to form an interior space of the lid. Similarly, each of the top paneland the plurality of wall panelshas an exterior surface that cooperate to form an exterior of the lid.

Attention is now directed to.illustrates an underside of the trayandillustrates a closeup view of a portion of the underside of the tray. As can be seen, the recessin the top or front surface of the primary panelforms a corresponding protruding portionon the bottom or back surface of the primary panel.

Additionally, the bottom or back surface of the trayalso has groovesformed therein. In the illustrated embodiment, the groovesare located where the primary paneland the plurality of flapsmeet. As can be best seen in, the groovesmay have wallsthat are angled relative to one another. For instance, the wallsin the illustrated embodiment are angled at about 900 relative to one another. In other embodiments, the wallsmay be angled more or less than 90°, such as 30°, 45°, 60°, 75°, 115°, 130°, 145°, 160°, or any other desired angle.

The angles wallsof the groovesmay facilitate folding of the plurality of flapsrelative to the primary panel. For instance, the groovesmay allow the plurality of flapsto fold relative to the primary panelto a predetermined angle. By way of example, when the grooveshave wallsthat are angled at about 900 relative to one another, the plurality of flapscan be folded relative to the primary panelso that the primary paneland each of the plurality of flapsforms an angle of about 90°. The groovesmay also allow the folds between the primary paneland the plurality of flapsto have a desired aesthetic, such as a relatively sharp outer contour.

In addition to the grooves, opposing edges of each flapmay also include a bevel or chamfer. The chamfersmay be oriented in the same direction and to the same angle as the groovesthat run colinear or parallel to the chamfer. In some embodiments, the groovesand chamfersare formed at the same time and with the same tool(s). For instance, the groovesand chamfersmay be cut into the traywith any suitable tool (e.g., knives, CNC, etc.).

The chamfersmay facilitate folding of the plurality of flaps. For instance, the chamfersmay allow the plurality of flapsto fold in a desired manner. By way of example, when the plurality of flapsare folded relative to the primary panel, the chamferson adjacent flapsabut one another and allow for the adjacent flapsto form a joint having a desired aesthetic, such as a relatively sharp outer contour (e.g. a substantially 90 degree edge).

In some embodiments, the protruding portionand the plurality of flapsmay have one or more dimensions that are similar or the same. For instance, each flapmay have a dimensionthat extends from an edge of the grooveto an outer edge of the flap(an edge opposite to the groove/primary panel). The dimensionmay be referred to as a “height” of the flap. Similarly, the protruding portionmay have a dimensionthat extends from the underside of a planar portion of the primary panelto an apex or plateau of the protruding portion. In some embodiments, the dimensions,are substantially equal to one another. Additionally, the dimensions,may be substantially equal to a height of the wall panelsof the base box.

Attention is now directed to, which illustrate an example process of assembling the base boxand the trayinto a base box assembly. The traycan be attached to the base boxto form the base box assembly. The attachment can be accomplished with the use of an adhesive. For instance, an adhesivecan be applied to the trayand/or the base box. In the illustrated embodiment, the adhesiveis applied to the underside of the tray. Specifically, the adhesiveis applied to the plurality of flaps. The adhesivecan be applied to substantially the entire lengths of the plurality of flaps, or at discrete locations on the plurality of flaps. The adhesivemay optionally also be applied to the protruding portion. In other embodiments, the adhesivecan be applied to the base box, including the exterior surfaces of the wall panelsand optionally the interior surface of the bottom panel.

The traycan then be associated with the base box. For instance, as shown in, with the underside of the trayfacing up, the base boxcan be positioned on the tray. More specifically, the base boxcan be positioned on the trayso that the protruding portionextends into the interior spaceof the base box. Additionally, the top edges of the wall panels(the edge opposite to the bottom panel) can be positioned adjacent to the grooves. The groovesmay be spaced apart from one another distances that are substantially equal to or only slightly larger than (e.g., 0.05 inches, 0.1 inches, 0.15 inches, 0.20 inches, 0.025 inches, etc.) the distances between the wall panels. For instance, the distance between the wall panelsmay be substantially the same as the distance between the inner edges of the grooves. As such, the top edges of the wall panelsmay engage the groovesor may be positioned towards an inside edge of the grooves. This allows the flaps, when folded along the grooves, to engage with the wall panelswithout material obstruction as shown in.

In other embodiments, the base boxcan be positioned with the interior spaceopening upwards or in another direction and the traycan be positioned thereon, with the protruding portionextending partially into the interior space.

When the base boxand the trayare so associated, as shown in, the protruding portionof the traycan extend into the interior spaceof the base box. In embodiments where the height of the convex portionis substantially equal to the height of the interior surface of the wall panels, the protruding portionmay extend into the interior spaceand contact the bottom panel, as shown in. When adhesiveis applied to the convex portionand/or the bottom panel, the adhesivecan secure the protruding portionto the bottom panel.

Notably, the plurality of flapsare not inserted into the interior spaceof the base boxwhen the base boxand the trayare associated with one another. As shown in, the plurality of flapsextend out beyond the wall panelsof the base box. The plurality of flapscan then be folded along the groovesso as to bring the plurality of flapsinto contact with the exterior surfaces of the wall panelsof the base box, as shown in. Specifically, the underside surfaces of the plurality of flapsare brought into contact with the exterior surfaces of the wall panels. The adhesiveon the plurality of flapsand/or the exterior surfaces of the wall panelscan secure the plurality of flapsto the exterior surfaces of the wall panels, as shown in.

Forming the base box assemblywith the plurality of flapsattached to the outside of the base boxcan provide the base box assemblywith a unique aesthetic. For instance, as shown in, top and side views of the base box assemblyhave a continuous, monolithic appearance. That is, the molded and folded trayprovides the top and sides of the of the base box assemblywith a unitary appearance without any seams between the recess, the planar portion of the primary panel, and the plurality of flaps. Furthermore, the chamferson the plurality of flapsallow for the plurality of flapsto form seamsthat substantially disappear and, rather, appear as a continuous surface across the corners of the base box assembly.

Additionally, the noted construction of the base box assemblyalso provides for a unique appearance to the underside of the base box assembly. The underside of a typical box will include a bottom surface and edge folds that extend into sidewalls of the box. In contrast, and as shown in, the underside of the base box assemblyincludes the bottom panelof the base boxand the edges of the plurality of flap, with a joint or seam.

illustrates a diagram showing a methodfor forming a packaging system according to an example embodiment. The methodcan include a stepof providing a base box, such as base box. As noted above, the base box can have a bottom panel and a plurality of walls that define an interior space. The plurality of wall can have exterior surfaces.

The methodcan also include a stepof providing a tray, such as tray. The tray may have a primary panel and a plurality of flaps extending from the primary panel. The primary panel may also have a recess that may be sized and configured to hold one or more products therein. The tray may be formed with a moldable material via a met molding or other process. In some embodiments, the methodalso includes forming grooves in the traybetween the primary panel and the plurality of flaps to facilitate folding of the flaps relative to the primary panel. Furthermore, the methodmay also include forming chamfers on edges of the flaps so that adjacent edges of the flaps form a desired angle (e.g., 90 degrees) when the flaps are folded.

The methodalso includes a stepof attaching the tray to the base box. In some embodiments, the stepincludes inserting the protruding portion of the tray into the interior space of the base box. Additionally, the stepmay also include folding and attaching the plurality of flaps of the tray onto the exterior surfaces of the plurality of walls of the base box.

According to one embodiment, a packaging system includes a base box having a plurality of walls defining an interior space, the plurality of walls having exterior surfaces. The packaging system also includes a tray attached to the base box. The tray includes a primary panel with a recess that extends at least partially into the interior space of the base box, and a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls.

In some embodiments, the tray comprises an underside having a groove formed therein between the primary panel and each of the plurality of flaps.

In some embodiments, each groove comprises opposing walls that are angled relative to one another.

In some embodiments, the opposing walls are angled relative to one another at an angle that enables the plurality of flaps to be folded to a predetermined angle relative to the primary panel.

In some embodiments, opposing ends of each of the plurality of flaps comprises a chamfer.

In some embodiments, the chamfers are angled to enable the ends of adjacent flaps to form a seam such that the adjacent flaps are oriented at a predetermined angle relative to one another.

In some embodiments, the tray is a monolithic component.

In some embodiments, the tray is formed of a moldable material.

In some embodiments, the each of the plurality of flaps has a dimension that is substantially equal to a dimension of the plurality of walls.

In some embodiments, the dimension of the flaps is a distance between a groove formed in the tray and an outer edge of the flap and the dimension of the wall is a height of the exterior surface of the wall.

In some embodiments, the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

In one embodiment, a packaging system includes a base box assembly and a lid.

The base box assembly includes a base box and a monolithic molded tray. The base box has a plurality of walls defining an interior space, with each of the plurality of walls having an exterior surface and an upper edge. The tray includes a primary panel and a plurality of flaps. The primary panel includes a planar portion that rests on the upper edges of the plurality of walls of the base box, and a recess that extends at least partially into the interior space of the base box. The plurality of flaps extend from the primary panel and are attached to the exterior surfaces of the plurality of walls. A plurality of folds are formed between the primary panel and the plurality of flaps. The lid has a top panel and a plurality of wall panels that cooperate to form and interior space that is configured to receive the base box assembly at least partially therein.

In some embodiments, the tray comprises a groove formed therein between the primary panel and each of the plurality of flaps.

In some embodiments, the grooves facilitate forming the plurality of folds.

In some embodiments, the recess is configured to receive a product therein for packaging within the packaging system.

In some embodiments, the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

In one embodiment, a method for forming a packaging system includes: providing a base box having a plurality of walls that define an interior space and have exterior surfaces; providing a tray having a primary panel and a plurality of flaps extending from the primary panel, the primary panel having a recess; and attaching the tray to the base box so that the recess extends at least partially into the interior space and the plurality of flaps are attached to the exterior surfaces.

In some embodiments, the method includes forming a plurality of grooves in the tray between the primary panel and the plurality of flaps.

In some embodiments, the method includes forming chamfers on opposing ends of each of the plurality of flaps.